Installation, Start- Up
And Service Instruction
30HR-HS
040, 050, 060
Reciprocating Liquid Chillers
30HR-HS 040 Model C and 30HR-HS 050,060 Model B
INSTALLATION
LOCATION
Accessory steel manifold packages for inlet and outlet
condenser water are available for 30HR units. Each manifold
is furnished in two sections, to be field welded as shown in
Fig. 1 Manifolds should not be used where regulating valves
are required because separate valves must be used on each
condenser circuit.
Set water-regulating valve to maintain design head
pressure. Do not adjust to compensate for high head pressures
caused by fouled condenser tubes, excess refrigerant or the
presence of non-condensable. Due to changes in water
temperature, it may be necessary to adjust the valve
seasonally, After adjusting for design head pressure, shut unit
down. Water regulating valve should shut off flow of water in
a few minutes. If it does not, it will be necessary to raise the
head pressure setting. Make sure that capillary tube from each
water-regulating valve is connected to the proper condenser
purge valve.
Condenser water must enter at bottom for proper operation
Units should not be stored where exposed to the weather
because of the sensitive control mechanisms and electrical
devices. Locate unit indoors.
See Fig. 1 and Table 1 for door clearances and space
requirements. Provide clearances at one end for removal of
tubes (Fig. 1, callouts 7 and 8).
Floor must be strong enough to support to operating
weight. If necessary, add supporting structure (steel beams or
reinforced concrete slab) to floor to transfer weight to nearest
beam(s).
All units have spring vibration isolators and mufflers.
Interconnecting piping must be flexible enough to prevent
vibration transmission. If vibration still exists, use isolators on
unit itself. If unit is installed on upper floor where vibration
cannot be transmitted to ground, use field-purchased vibration
mountings under each mounting hole. Back off mounting lock
bolts to allow compressor to float freely: otherwise, excessive
vibration will result.
Move unit on its skid to final location. If using chain hoist,
use a spreader bar so that control boxes will not be damaged
by sling. Place sling under skid. Do not attach sling to piping
or component. Move unit in upright position: lower gently
from truck or rollers. Use enough pipes to support skid when
rolling.
Figure 1 shows location mounting holes. Areas where
corners will be located must be level before unit is placed.
Level unit with spirit level on frame channels. Bolt unit to
floor (recommended for basement or ground floor installations
that transmit vibration to ground without affecting building
structure).
See Table 2 for weight distribution.
of the internal sub cooler in the bottom of the condenser (Fig. 1).
CAUTION: Retighten all condenser head bolts before filling
system with water.
Discharge pipe from high side pressure relief valve (HR units)
must not be smaller than valve size. HS units require fieldinstalled high side pressure relief valve near condenser in each
refrigerant circuit. Most local codes require piping from valve
to outdoors.
Water leaving condenser is under pressure and should not
be connected directly into sewer lines. Check local codes. A
3/8-in. drain plug is located at each end of each condenser.
NOTE: provide means for draining system in winter and for
repairs.
CONDENSER
Two check valves and two pressure relief valves are
shipped loose with each condenser less (HS) unit as
standard equipment, Install one of each in the discharge
line of each refrigerant circuit, downstream of the hot gas
muffler. Locate the relief valve close to remote condenser.
There must be no shutoff device between relief valve and
condenser; Installation of these valves must be in
compliance with all applicable codes
Run water supply lines as short as possible. Size lines
according to head pressure available (not necessarily
connection size), especially on cooling tower application. See
system Design Manual, Part 3, Piping Design.
For installation requiring a water regulating valve, a
separate valve is required (not supplied by carrier) for each
refrigerant circuit. Water regulating valve must be installed on
cooling tower application where low outdoor ambient affect
head pressure.
The 30HS unit using air-cooled or evaporative condensers
should have adequate means for head pressure control when
operating below 60 F outdoors ambient.
1
Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install safety valves in
series or backwards.
Repair safety consideration
The personnel in charge must maintain all installation
parts, in order to avoid material deterioration and injuries
to people. Faults and leaks must be repaired immediately.
The authorized technician must have the responsibility to
repair the fault immediately. Each time repairs have been
carried out to the unit; the operation of the safety devices
must be re-checked.
CAUTION: Do not step on refrigerant lines. The lines can
break under the weight and release refrigerant, causing
personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
If a leak occurs, evacuate all refrigerant, repair the leak
detected and recharge the circuit with the total R407C or R22
charge, as indicated on the unit name plate. Only charge liquid
refrigerant R407C or R22 at the liquid line (see chapter "
Refrigerant charge ".)
Use mechanical lifting equipment (crane, hoist, winch, etc.) to
lift or move heavy components. For lighter components, use
lifting equipment when there is a risk of slipping or losing
your balance.
Ensure that you are using the correct refrigerant type before
recharging the unit (see unit name plate).
Use only original replacement parts for any repair or
component replacement. Consult the list of replacement parts
that corresponds to the specification of the original equipment.
Charging any refrigerant other than the original charge type
will impair machine operation and can even lead to a
destruction of the compressors.
Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body first.
Do not use oxygen to purge lines or to pressurize a machine
for any purpose. Oxygen gas reacts violently with oil, grease,
and other common substances.
Close the entering and leaving water shutoff valves and purge
the unit hedonic circuit, before working on the components
installed on the circuit (screen filter, pump, water flow switch,
etc.).
Never exceed the specified maximum operating pressures.
Verify the allowable maximum high-and low side lest
pressures by checking the instructions in this manual and the
pressures given on the unit nameplate.
Periodically inspect all valves, fittings and pipes of the
refrigerant and hedonic circuits to ensure that they do not
show any corrosion or any signs of leaks.
Do not use air for leak testing. Use only refrigerant or dry
nitrogen.
Do not unwed or flame cut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid and
vapor) has been removed from chiller. Traces of vapor should
be displaced with dry air nitrogen. Refrigerant in contact with
an open flame produces toxic gases.
The necessary protection equipment must be available, and
appropriate fire extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles. wash any spills from the skin
with soap and water . If liquid refrigerant enters the eyes,
immediately and abundantly flush the eyes with water and
consult a doctor.
Never apply an open flame or live steam to a refrigerant
container. Dangerous overpressure can result. If it is necessary
to heat refrigerant, use only warm water.
Do not re-use disposable (non-returnable) cylinders or
Attempt to refill them. It is dangerous and illegal. When
cylinders are empty, evacuate the remaining gas pressure, and
move the cylinders to a place designated for their recovery.
Do not incinerate.
Do not attempt to remove refrigerant circuit components or
fittings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 KPa before removing
components or opening a circuit.
2
15
N
M
L
MTG HOLE
C
L
P
REFRIG
INLET
REFRIG
DISCHARGE
17
K
1'-6 1 4 "
CL
1'-7"
CL
2'-1 5 8"
MTG
HOLES
16
30HS TOP VIEW
30
30HS END VIEW
MTG HOLE
8
3
1'-3 4 "
BOTH ENDS
27
28
29
6'-5 3 4 "
5
J
9
10 3 4 "
DIAM
18
CL CONDENSER
10"
2'-6 3 4 "
1'-5"
H
1'-0 3 16 "
CL
3'-0"
MTG
HOLES
1'-1 1 4 "
10
F
13
12
7
30HR TOP VIEW
11
30
4'-1 1 2 "
START BUTTON
STOP BUTTON
21
G
1'-1 3 8"
30HR END VIEW
9'-0 3 8"
23
22
26
25
6
WATER
OUT
WATER
IN
CONTROL
PANEL
20
FIELD WELDED
2'-11 3 4 "
24
2'-7 1 8 "
E DIAM
C
L COOLER
ACCESSORY WATER MANIFOLDS AND CONDENSER
NOZZLE ARRANGEMENT VIEWED FROM FRONT
OF UNIT.
2
30HR , HS
FRONT VIEW
4
3
C
1
INLET
D
C
4'-6 1 2 " CL
MTG HOLES
B
A
LEGEND
1 – 3-in FPT Water inlet
12 – Cut hole in removable plate for power inlet
2.1/2-in max conduit size
– Unloaded Solenoid. One on each compressor
2 – Temperature Controller Bulb
13
3 – 3 in FPT Water Outlet
14 – Oil safety Switches. Manual reset
4 – 1-in FPT Water Drain Conn.
15 – 7/8-in ODF Refrigerant Liquid Inlet from
22 – Compressor no. 1:6 cylinder for
040, 050 and 060
23 – Compressor no 2:4 cylinder for
040, 050, 6-cylinder for 060
24 –Liquid Line Solenoid Valve (one each CKT)
(Std equipment on HS. accessory on HR)
16
condenser circuit no. 1
– 7/8-in ODF Refrigerant liquid Inlet from
condenser circuit no. 2
– 1.3/8-in ODF Discharge Line. Circuit 1 and 2
6 – 1/4-in SAE Flare Field Charging Valve (2)
17
7 – Space
18 – Replaceable core Filter Driers, one each
required to remove cooler tubes
(either end)
8 – Space required to remove condenser tubes
(either end)
9 – 2.1/2 - in diameter SCH 40 removable
nozzles (each end of both condensers)
10 – Low Water Temp Cutout Bulb
1 –Three 7/8-in knockouts. Two on top and one
on back of control box
circuit. HR, HS040 one core each HR
HS050 two cores circuit 1,one core
circuit 2 HR HS060 2 cores each
25 – Water inlet Manifold (accessory) 4-in
150 lb ASA flat-face flange
(accessory) 4-in
150-ib ASA flat-face flange
– 5/8-in SAE Flare Pressure Relief Valve
(each condenser)
– 1/4-in Flare Conn. for water reg. valve
(each condenser)
26 – Water Outlet Manifold
27
28
19 – Compressor Sequence Switch
29 – 1/4-in Purge Valve (each condenser)
20 – Circuit Breakers
21 – Gage Panel (accessory) both sides
30 – Field Installed Control Transformer
Fig. 1 – Dimensions
3
(accessory). (In control panel,
adjacent to main terminal (block.)
Table 1-PHYSICAL DATA
HR040
Table 2-WEIGHT DISTRIBUTION
HS040
HR050
HS050
HR060
HS060
UNIT 30
UNIT
30
DIM. (Ft-in)*
(Refer
A
7– 6
To
B
1– 5
Fig. 1)
C
0– 10
D
0– 4
3
E
0– 10
3
F
7– 0
1
G
0– 5
1
H
0–
Comp 2
9
0– 6
J
Comp 1
3
9– 0
1
2– 2
7
1– 6
1
4
1– 1
3
4
1– 0
3
2
9– 3
1
2
0– 4
1
1
4
0– 10
1
8
0– 6
1
4
7
K
–
3– 8
3
K
–
3– 8
3
L
–
1– 4
3
M
–
1– 5
5
N
–
0– 5
1
P
–
0– 5
1
2640
NET WT (lb)
REFRIG R407C
CHG (lb) †
TOTAL
OIL CHG (L)
CONDENSERS
09RP022
09RP027
Length (ft - in)
Number
Area ( sq ft )
Inside
Outside
SUBCOOLER
TUBES
Length (ft-in)
Number
Area (sq ft)
Inside
Outside
NO. CIRCUITS
NO. PASSES
7
4
1– 6
1
4
1– 1
3
4
1– 0
3
2
9– 3
1
2
0– 4
1
4
0– 10
1
4
0– 6
1
–
3– 8
3
–
1– 1
3
–
1– 3
5
–
0– 11
3
–
0– 11
3
1740
3065
2115
40
84‡
8
8
8
2
2
13.24
4
8
8
8
4
4
49
–
–
–
1
1
4
–
–
3– 9
1
–
1– 3
5
–
1– 3
5
–
0–11
3
–
0–11
3
3180
2180
Location of mounting holes:
4
4
8
8
The sensing bulb of the chilled water temperature
controller is in a well in the return water connection. The
temperature controller is factory set to control from return
chilled water.
Plan piping for minimum number of changes in elevation.
Install manual or automatic vent valve at high points in line.
Maintain system pressure by using a pressure tank or
combination relief and reducing valve.
See Carrier System Design Manual, Part 3, Piping, for
chilled water piping details.
Install thermometers in entering and leaving lines. Provide
drain connections at all low points to permit complete
drainage of system. Connect shutoff valve to drain line before
operating unit. Install shutoff valve near entering and leaving
water connections. Use flexible connections on condenser and
cooler piping to reduce vibration transmission.
Insulate piping after leak testing to prevent heat transfer and
sweating. Cover insulation with moisture seal.
4
4
56
–
–
09RP027
30HR
050, 060
5– 10
OD Fins, 40/ in.
5– 10
1
4
129
36
44
–
–
273
273
36.0
117
44.8
145
–
5– 10
1
REFRIGERANT CHARGE
Refrigeration installations must be inspected and
maintained regularly and rigorously by specialists. Their
activities must be overseen and checked by properly trained
people. To minimize discharge to the atmosphere, refrigerants
and Lubricating oil must be transferred using methods, which
reduce leaks and losses to a minimum.
 Leaks must be repaired immediately
 All units are equipped with two special connections on
the suction and liquid line, which permit the connection
of quick-connect recovery valves without loss of
refrigerant.
 If the residual pressure is too low to make the transfer
alone, a purpose-built refrigerant recovery unit must be
used.
 Compressor lubricating oil contains refrigerant. Any oil
drained from a system during maintenance must therefore
be handled and stored accordingly.
Refrigerant under pressure must never be discharged to
the atmosphere
4
–
–
–
–
4
13
2 (refrig)
4 (refrig)
3 (water)
5
–
CONNECTIO (in)
REFRIG
Liquid
(2) 1
1
Suction
(2) 2
1
MDWP (psig)
Water side
Refrig side
8
ODM
(See Fig. 1)
8
ODM
–
250
235
B
475
590
610
4
–
4
HS
A
475
590
610
4
2
3
HR
A
B
970
490
1150 580
1200 600
2
1
040, 050
HS
1900
2360
2440
2
–
09RP022
HR
2920
3460
3590
LOAD PER MTG HOLE (lb)
4
CONDENSER
Prime Surface
6– 2 1 2
6– 10 1 2
129
4
18
6– 8 1 2
4
4
3– 9
87‡
040
050
060
8
–
15.6
2
1
2– 2
1
71‡
6– 0
8
3– 9
30HR, 30HS
040
050, 060
SHELL
Length (ft - in)
TUBES
1
–
8
COOLER
UNIT
4
9– 0
APPROXIMATE
OPER WT (lb)
250
385
MDWP–– Maximum Design Working pressure
* Dimensions common to all units are shown in Fig 1.
† HR units have operating charge. HS units have holding
charge (for operating charge, add listed HS charge to field
piping and remote condenser charges).
‡ In condenser when shipped; between
liquid valve and
compressor discharge valve
4
Recharging liquid refrigerant
NOTE: Use only oils, which have been approved for the
compressors. Never use oils, which have been exposed to air.
CAUTION:HR units are charged with liquid R22
refrigerant.
NOTE: Regularly carry out leak checks and immediately
repair any leak found.
Recommended Oils:
 R407C compressors:
- Carrier specification: PP 47 26
- Mobile oil EAL 68 (original charge)
 R22 compressors:
- Mineral oil, Carrier specification: pp 3326
-Gargoyle Artic (Mobil Oil, original charge)
- Suniso 3 GS (Sun Oil Co.)
Undercharge
If there is not enough refrigerant in the system, this is
indicated by gas bubbles in the moisture sight glass.
CAUTION: R407C oils are absolutely not compatible
with R22 oils.
If the undercharge is significant, large bubbles appear in the
moisture sight glass, and the suction pressure drops. The
compressor suction superheat is also high. The machine must
be recharged after the leak has been repaired.
Find the leak and completely drain the system with a
refrigerant recovery unit. Carry out the repair, leak test and
then recharge the system
Table 3-ELECTRICAL DATA
COMPLETE UNIT AND COMPRESSORS
VOLTS
UNIT 30
*
230
MKW
WSA
400
ICI
WSA
ICF
ICI
319
355
355
319
355
355
81
83
97
90
98
117
234
234
248
238
238
257
205
205
205
205
205
205
MTA
FLA
LRA
MTA
69
80
106
80
120
29
33
43
33
52
110
144
205
144
205
41
46
60
46
73
ICF
IMPORTANT: After the leak has been repaired, the
circuit must be tested, with out exceeding the maximum
low-side operating pressure shown on the unit nameplate.
040
050
060
040
HS
050
060
COMP R
06E
43.5
44.2
53.6
49.6
50.9
61.12
150
250
275
250
275
17.4
20.0
26.8
20.0
30.9
HR
The refrigerant must always be recharged in the liquid
phase into the liquid line.
The refrigerant cylinder must always contain at least 10%
of its initial charge.
CAUTION: R407C Oils are absolutely not compatible with
R22 oils.
HR
HS
OIL CHARGE
KW
138
144
171
156
165
194
FLA
49
57
76
57
86
368
404
431
376
412
441
LRA
191
250
255
250
355
Table 4-COMPRESSOR 06E USAGE†
All units are factory charged with oil. If oil is visible in
sight glass, start compressor. Observe level and add oil, if
required, to bring Level in Crankcase to middle of bull , s-eye
during steady operation. To add or remove oil see Standard
Service Techniques Manual, Chapter 1, Refrigerants.
NOTE: To ensure trouble-free operation, use only
Recommended oil, see below Do not reuse oil that has been
drained out, or oil that has been left open to the atmosphere.
UNIT
30
040
050
060
HS
HR
Circuit and Compressor Numbers
1
2
1
2
B250
B150
B250
B250
J275
B150
J275
B250
J275
J275
J275
J275
Full Load Amps
Maximum Instantaneous Current Flow (amps) during
starting (sum of LRA for last compressor to start plus FLA for
all other running compressors).
Maximum
Incremental Current Inrush (amps) during
ICI
starting (LRA for largest compressor in unit).
Maximum Input Power (each compressor).
KW
Locked Rotor Amps
LRA Maximum Unit Input Power
MKW Must Trip Amps
MTA Wire Sizing Amps per NEC, Section 430-24
WSA * Suitable for use on electrical systems where voltage supplied to unit
terminals is not
below or above the following limits:
Max 264 volts, min 198 volts for 230 – volt units.
Max 457 volts. Min 342 volts for 400 – volt units.
† Compressor numbered from left to right when viewed from front of unit.
Each compressor has electric unloaded on one cylinder bank (2 cylinders).
NOTES:
1. Compressor speed-1450 rpm.
2. Crankcase heater-180 watts, 240 volts.
3. Maximum allowable phase unbalance: volts, 2%; amps, 10%
4. Maximum incoming wire size: 350 MCM for 230-volt units;
no. 0000 AWG for 400-volt units.
FLA
ICF
To Add Oil - Close suction shutoff valve and pump down
crankcase to 2 psig. (Low-pressure cutout must be jumpered.)
Wait a few minutes and repeat as needed until pressure
remains at 2 psig. Remove oil fill plug above bull , s-eye, add
oil thru plug hole and replace plug. Run compressor for about
20 minutes and check oil level.
To Remove Oil-pump down compressor to 2 psig. Loosen the
1/4- in. pipe plug in compressor base and allow the oil to seep
out past the threads of the plug. The crankcase will be under
slight pressure. Be careful not to remove the plug; the entire
oil charge may be lost. Small amounts of oil can be removed
while compressor is running thru oil pump discharge
connection.
The compressors installed in these units have an oil charge
(91) to ensure their correct operation.
Check that the oil level is between 1/8 and 3/8 up the sight
glass before start-up and after normal unit operation.
5
-
START-UP AND SERVICE
INITIAL CHECK
Crankcase heaters should be energized at all times when
unit is not in operation. On 50-Hz units. Each heater is 180
watts, 240 volts. Never open any switch that will de-energize
crankcase heaters unless unit is being serviced or shut down
for a prolonged period. These switches include the unit field
power supply switch (unless control circuit power is from
separate source) and the control circuit switch or breaker. If
control circuit power is from separate source, the fused
disconnect must be kept closed. After a prolonged shutdown
or service job, energize crankcase heaters 24 hours before
starting compressors.
Do not attempt to start the liquid chiller even
momentarily unit the following steps have been completed.
1. Check all auxiliary components such as chilled liquid
circulating pump, cooling tower if used, air handling
equipment, or other equipment to which the chiller
supplies liquid. Consult the manufacturer , s instructions
2. Check safety thermostat. See Safety Thermostat for
adjustment.
3. Backseat (open) compressor suction and discharge
shutoff valves. Close valves one turn to allow
pressure to reach gages.
4. Open liquid line shutoff valves at condensers.
5. Open valves to capillaries of water-regulating valves
(when used)
6. Fill chilled liquid circuit completely with clean water
or other non-corrosive. fluids to be cooled. Bleed
all air out of high points of system.
7. Open supply valve (or fill cooling tower if used ) for
condenser cooling water.
8. Set temperature controller.
9. Check tightness of all electrical connections.
10. Check compressor oil (should be visible in bulls-eye).
11. Be sure unit is fully charged with refrigerant
(see Refrigerant Charge).
12. Be sure crankcase of each compressor is warm
(heaters should be on for 24 hours before starting
compressors).
COMPRESSOR REPLACEMENT
If a replacement 6-cylinder compressor has center-bank
cylinder head with discharge valve pad facing pump end,
remove the head and install reverse flange head from original
compressor (discharge valve pad toward motor end ).
Center-bank cylinder head cannot be rotated 180 o.
CIRCUIT BREAKERS
One breaker for each compressor provides three-leg
overload protection. Do not bypass connections or increase
size of breaker to correct trouble. Determine the cause for the
trouble and correct before resetting breaker. Throwing off,
then on again must manually reset tripped breaker. See circuit
breaker trip amps in Table 3, Electrical Data. CIRCUIT
BREAKER KITE RESET
START-UP
Start-up should be performed only under supervision of
experienced refrigeration mechanic.
1. Open all system valves that may have been closed
during or after charging.
2. Check air-handling equipment, chilled water and
condenser water pumps, and any other equipment
connected to chiller.
3. Start unit by pushing START button.
4. Check all controls for proper operation.
5. Adjust water-regulating valve to most economical
head pressure ( based on relative cost of water and
electricity).
6. Check chilled water leaving temperature to see that it
remains well above freezing.
7. Check compressor oil level (see Oil Charge).
HIGH-LOW DUAL PRESSURE SWITCH
One switch provided in each refrigerant circuit See
Table 6.
High-pressure switch-To check, jumper the normally -open
control relay contacts. Slowly close discharge shutoff valve
until compressor shuts down (should be at cutout pressure
shown in Table 5). Reopen discharge shutoff valve.
Compressor should start when pressure drops to cut-in point
shown
Low-pressure switch-To check, close suction shutoff valve
and allow compressor to pump down. It should stop when
suction pressure drops to cutout point shown in Table6.
Compressor should restart automatically when suction
pressure builds up to cut-in point shown.
CRANKCASE HEATERS
For winter start control where HS units are coupled with
air-cooled
condensers, move low-pressure switch
connection from suction side of system to a pressure tap
liquid line and reset to cutout at 5 psig leaving differential
same (50 PSI). A 1/4in. flare connection is provided on HS
units between liquid line solenoid nd TXV.
Heaters are furnished on all compressors to prevent
refrigerant absorption by oil in the crankcase during
shutdown. Located in bottom cover of compressor, heater is
held in place by clip and bracket. Make sure heater is tight to
prevent it from backing out when operating. Heater will burn
out if exposed to air for an extended length of time. Heater is
wired into control circuit by connecting it to normally closed
auxiliary contacts on compressor starter.
NOTE: Check both switches at start-up and least once
each year.
6
Table 5-PRESSURE SWITCH SPECIFICATIONS
CUTOUT
CUTIN
UNIT30
Psig
Kpa
Psig
Kpa
42±3
290±21
57±5
393±34
Low Pressure
CUTOUT
CUTIN
High Pressure
Psig
Kpa
Psig
Kpa
280±10 1931±69 180±20 1241±138
HR
375±10 2585±69 275±20 1896±138
HS
MOISTURE-LIQUID INDICATOR
Clear flow of liquid refrigerant indicates sufficient
charge in system. Bubbles indicate under-charged system or
presence of non-condensable. Moisture, measured in parts per
million (PPM), in system will change color of indicator.
Green moisture is below 330 PPM: chartreuse (caution) 380 to
550 yellow (wet)- above 550 change filter-drier cores at first
sign of moisture in system. Each refrigerant circuit has an
indicator.
With unit running, indicating element must be in contact
with liquid refrigerant to give true moisture indication. 30HS
units (shipped holding charge only) must be fully charged and
run before moisture content can be determined.
OIL PRESSURE SAFETY SWITCH
Standard on 30HS units, accessory for 30HR (see Fig. 2 for
wiring connections). To test, bypass pressure switch with
jumper. Compressor should stop in about 120 seconds. If it
continues to run for more than one minute, and nothing is
wrong with the wiring, replace switch. Be sure differential
switch closes when compressor stops. Switch setting requires
pressure rise to 9 psig in 120 seconds and oil pressure above 4
psig for compressor operation. After test, allow 5 minutes for
thermal switch to cool, then press reset button.
If the safety switch stops the compressor, find trouble and
correct before attempting to restart.
LIQUID LINE SOLENOID VALVE
One valve in each refrigerant circuit prevents liquid
refrigerant from migrating to cooler during shut down.
ELECTRICALLY EXPANSION VALVES
These valves control flow of liquid refrigerant by
maintaining constant superheat of vapor leaving cooler.
Factory set to maintain a superheat of 6C; do not adjust setting
unless absolutely necessary. There is one valve for each
refrigerant circuit. See catalogue for more details.
THERMAL EXPANSION VALVES
These valves control flow of liquid refrigerant by
maintaining constant superheat of vapor leaving cooler.
Factory set to maintain a superheat of 8-10 F; do not adjust
setting unless absolutely necessary. There is one valve for
each refrigerant circuit.
Fig 2-Oil Pressure Safety Switch Connection Diagram
CAPACITY CONTROL
COMPRESSOR THERMAL PROTECTION
Capacity control is a system, which cycles compressors
as well as loads and unloads cylinders in each compressor to
maintain load requirements. Includes a 4-step temperature
controller and two cylinder bank unloadeds. Table 6 shows
capacity control steps.
Four-Step Temperature Controller consists of four load
switches actuated by pressures developed in a temperaturesensing bulb located in the return water nozzle of the chilled
water system. The controller is factory set to control from
return water temperature thru a cooling range of 10 F.
The sequence switches are factory calibrated and sealed
and should not require any field changes.
If a different return-water cooling range or a leavingwater control is specified, or if brine is to be used the
controller must be changed. Consult local Carrier
representative for proper control device.
The temperature at which the last step of capacity
unloads indicated by the design set point on the adjustable dial
(Fig. 4). Example: design set point is at 44 F. On a reduction
in load, the Capacity of the unit will be reduced to zero when
return water temperature drops to 44 F.
WARNING: Any alteration of factory settings, except design
set point, without Carrier authorization may void the Carrier
Warranty.
A discharge thermostat installed in one cylinder head of
each compressor, senses an over temperature condition. If the
discharge gas temperature of any compressor exceeds
295  5F,the thermostat opens and shuts off that compressor
and the other compressor in the circuit. The thermostat reset
temperature is approximately 250 F. See Fig.3 For switch
connections.
DT1
4
CR1
23
TB3
DT2
4
21
CR2
CI R CU IT N o.2
DT
TB
TB4
- Discharge Temperature Switch
- Terminal Block (unit)
- Terminal on unit terminal block
- Terminal Connections (Marked)
Fig3-Discharge Temperature Switch Connections.
7
Table 6-CAPACITY CONTROL
CONTR
STEPS
UNIT
30HR
30HS
1
2
3
4
1
2
3
4
1
2
3
4
040
050
060
LLSV
(=
Open)
OPERATION
TRANS SW* POS1
Oper Cyl
%
Ck t
Cap Total
1
2
TRANS SW* POS2
Oper Cyl
%
Ck t
Cap
1
2
40
60
80
100
33
66
83
100
-
20
60
80
100
33
66
83
100
-
4
6
8
10
4
8
10
12
-
4
4
6
6
4
4
6
6




Sequence of Control-Power is supplied to Control circuit
either from a separate source or thru a field-installed
transformer (accessory package) with primary connected to
unit power terminal block (installation instructions furnished
with accessory transformer package). Control circuit is
energized thru a circuit breaker on control panel. This server
as ON-OFF switch for control circuit.
Crankcase heaters are wired they are operative as long as
control circuit breaker is on, regardless of condition of other
safety devices. When a compressor stops, its heater is turned
on to prevent refrigerant absorption by oil in the crankcase.
Control circuit breaker should be off only when unit is
being serviced. After a prolonged shutdown, energize
crankcase heaters for 24 hours before starting compressors.
With power to control circuit terminals 15 and 16 and
control circuit breaker in "on" position, unit is ready for
operation providing all safety devices are satisfied, interlocks
are closed and instructions on warning labels have been
followed.
Total
2
2
4
4
4
6



2
6
8
10
4
8
10
12
-
4
4
6
4
4
6



2
2
4
4
4
4
6
6




LLSV – Liquid Line Solenoid Valve
* Transfer Switch, manually operated.
Compressor starting sequence: Pos 1, 1-2: Pos 2, 2-1.
DESIGN SET POINT ADJUSTMENT
Adjust set point by Rotating switch in the panel.
When the START-STOP switch is turned to "Start", the
panel light will come on and timer motor will start. If
temperature controller is calling for cooling, No. 1 compressor
will start immediately. After 15 seconds, if required by load
demand, no. 2 compressor will start. At this point, timer motor
will stop with timer switch contacts A-A1 and B-B1 made;
temperature controller then takes over. This timer position
will hold during unit operation, while temperature controller
cycles compressors off and on and alternately loads and
unloads cylinders in each compressor to control cooling
capacity in response to load requirements.
Operator should use sequence transfer switch on control
panel to change lead compressor periodically: this equalizes
compressor wear. A panel light for each circuit shows which
compressor is running. Stop unit before changing starting
sequence.
0
О
C
SET POINT ADJ.
SET POINT
L.W& SET POINT DISPLY
О
L.W.T
4
О
3
О
2
О
1
О
SET INDICATORS
Unit Stoppage (other than supply power interruption)- Watercooled (30HR) units and condenser less (30HS) units
completely stop if the START-STOP switch is turned to
"Stop", low water temperature cutout contacts open, contacts
of any auxiliary interlock in the chilled water system open, or
control circuit breaker trips.
ON
ON
ON
ON
ON
ON
ON
ON
220
SENSOR
STEPS OUTPUT
Fig .4 set point Adjustment
Table 7– CIRCUIT DATA
UNIT 30HR,HS
CIRCUIT NO.
Compressor No*
Comp. Size (nom tons)
No. Comp. Cylinders
No. Comp. Unlooders†
040
1
1
20
4
1
050
2
2
20
4
1
1
1
30
6
1
060
2
2
20
4
1
1
1
30
6
1
Individual Compressor Stoppage-Motor winding thermal
protector contacts open, high- or low-pressure switch
2
2
30
6
1
in the refrigerant circuit opens, oil pressure safety switch
opens, or contacts of any auxiliary interlocks in refrigerant
circuit open. Safety devices in one circuit do not affect
operation of other circuit. A tripped main-power circuit
breaker will stop the compressor in that circuit.
Besides stopping compressor, the following devices close
liquid line solenoid valve in each refrigerant circuit; internal
motor thermal protectors, oil safety switch, high– pressure
switch. Cutout of low-pressure switch will not close liquid
line valve.
Restart After Stoppage By Safety Device
LOW WATER TEMPERATURE CUTOUT–Manually
depress reset button on control panel.
* Numbered left to right, viewed from front of unit.
† Electric solenoid type.
8
CAPACITY CONTROL SYSTEM
Capacity Control Electric – Electrically operated control valve is actuated by remote signal to the electric solenoid coil, which has
the same voltage as the unit control voltage, No manual adjustments to the electric unloaded valve are necessary. When the solenoid
is "de-energized", the passageways in the valve are aligned for "loaded" Conditions. When the solenoid is " energized" the valve
passageways are aligned for unloading.
LOADED OPERATION
This capacity control valve is controlled by an electric solenoid. When the solenoid is de-energized, the valve loads the cylinder
bank (2 cylinders) as show in the above figure.
When the suction pressure rises above a set point, an external controller de-energizes the solenoid coil. This closes the capacity
control valve port, allowing discharge pressure to build-up behind the unloaded piston assembly. A high enough pressure will
compress the unloaded valve spring, opening the unloaded suction port. Suction gas can now be drawn into the cylinders, running the
bank fully loaded.
UNLOADED OPERATION
As the suction pressure drops below the set point of an external controller, the solenoid coil is energized. This opens the capacity
control valve port, allowing the discharge gas behind the unloaded piston assembly to vent back to the suction side. The unloaded
valve spring at this point can move the unloaded valve body to the left, blocking the unloaded suction port. The cylinder bank is now
isolated from the compressor suction manifold, unloading these two cylinders. No refrigerant is allowed into the cylinders and no
compression takes place.
Operation for plc seires For learning how to work with controller see manual catalogue.
9
Servicing 30HR Units-If it is necessary to open both main
power circuit breakers, first turn the control circuit STARTSTOP switch to "Stop".
MOTOR WINDING THERMAL PROTECTOR OR
HIGH-PRESSURE SWITCH – Turn START-STOP
Switch to "Stop", then to "Start". Entire unit stops; restart is
under timer control.
LOW-PRESSURE SWITCH-Automatic restart when
pressure rises to cut-in point.
OIL PRESSURE SAFETY SWITCH-Manually depresses
reset button devices and turn START-STOP switch to "Stop"
and then to "Start".
If any safety device action repeats. Do not make a second
attempt to restart unit until the cause is determined and
corrected.
This de-energizes (and closes) the liquid line valves and
energizes the crankcase heaters while the compressors are off.
If only one main power circuit breaker will be open, first turn
the control circuit START-STOP switch to "Stop" and then
disconnect the control relay holding Coil in the control circuit
for the compressor that will be off This will de-energize the
liquid line valve for that circuit and energize the crankcase
heater for the off compressor. Then turn the control circuit
START-STOP switch to "Start” to restart the operable
compressor.
Timer Controlled Restart- when power is restored after an
interruption; restart is automatic thru normal timer-controlled
cycle. When control circuit is reenergized, approximately 5
minutes will elapse before first compressor is energized.
When START-STOP switch is turned to "Stop" or when
low water temperature cutout opens during unit operation,
timer will start, run for approximately 5 minutes and stop.
Timer is now set for first compressor to start immediately
when operation is resumed.
On 30HS units, the oil pressure safety switch(es) for the
off compressor(s) will open, causing the liquid line valve(s) to
close. The control circuit will remain energized and the
crankcase heater(s) for the off compressor(s) will energize. At
restart, depress the reset button on the oil safety switch, and
turn the START-STOP switch to "stop” then to "Start
TROUBLESHOOTING
SYMPTOMS
Compressor
does not run
PROBABLE CAUSE
Power line open
Control circuit breaker
tripped
Safety
thermostat
tripped
Tripped power breaker
Condenser circulating
pump not running
Loose
terminal
connection
Improperly
wired
controls
Low line voltage
Compressor
defective
Compressor
cycles on low
pressure control
motor
Seized compressor
Low-pressure
control
erratic in action
Compressor suction
Valve leaking
Compressor
suction
Shut off valve partially
closed
Low refrigerant charge
REMEDY
Reset circuit breaker
Check control circuit
for ground or short
Reset breaker
Reset thermostat
Check the controls.
Find cause of trip and
reset breaker
Power off-restart
Pump binding-free
pump
Incorrect
wiring
rewire
Pump motor burned
Out-replace
Check connections
SYMPTOMS
Compressor
Cycles on lowPressure control
PROBABLE CAUSE
Plugged compressor
Suction strainer
REMEDY
Clean strainer or
Replace
Compressor
Cycles on high
Pressure control
High-pressure control
Erratic in action
Check capillary tube
for pinches
Set
control
as
required
Open
valve,
or
replace
if defective
Purge
Clean condenser
Start pump repair or
replace if defective
Add refrigerant
Replace control
Purge
Clean or replace
Compressor discharge
valve partially closed
Unit operates long
or continuously
Check wiring and
rewire
Check line voltagedetermine location of
voltage drop and
remedy deficiency
Check motor winding
for open or short replace compressor, if
necessary
Replace compressor
Raise
differential
setting
Check capillary for
pinches
Replace control
Replace valve plate
Air in system
Condenser scaled
Condenser water pump or
fans not operating
Low refrigerant charge
Control contacts fused
Air in system
Partially plugged or
plugged expansion valve
or strainer
Defective insulation
Service load too high
Inefficient compressor
System noises
Piping vibration
Expansion valve hissing
Compressor noisy
Open valve
Replace or repair
Keep doors and
windows closed
Check
valves,
replace
If necessary
Support piping as
required
Check for loose pipe
connectors
Add refrigerant
Check for plugged
liquid line strainer
Check valve plates
for valve noise
Replace compressor
(worn bearings)
Check for loose
compressor
hold
down bolts
Add refrigerant
10
TROUBLESHOOTING (Cont)
PROBABLE
CAUSE
Symptoms
Compressor
Loses oil
Leak in system
Plugged
or
stuck
compressor snifter valve
Oil trapped in line
Frosted
or
sweating suction
line
Hot liquid line
Frosted liquid line
Compressor will
Not unload
Compressor
not load
High suction
will
Crankcase heaters not
energized
during
shutdown
Expansion
valve
admitting
excess
refrigerant
Shortage of refrigerant
due to leak
Expansion valve opens
too wide
Receiver shut off valve
partially
closed
or
restricted
Restricted filter drier
Burned out coil
Leaky bypass piston
Stuck needle valve
Misfired solenoid
Plugged bypass point
(low side)
Weak bypass piston
spring
Damaged bypass piston
Stuck needle valve
Misfired solenoid
Plugged bypass port
strainer (high side)
Stuck check valve in
valve plate
REMEDY
Symptoms
Repair leak
Repair or replace
Check piping for oil
traps
Replace heaters check
wiring and auxiliary
contacts
Adjust expansion valve
PROBABLE
CAUSE
Chattering
unloaded
Stuck check valve
in valve plate
Examine check valve
clean or replace as
necessary
Freeze - up
Improper charging
Make sure that a full
quantity at water is
flowing thru the cooler
while charging and
that suction pressure
in cooler is equal to or
greater than that
corresponding to 32F
(53
psig
for
Refrigerant R407C)
Improperly set safety
thermostat
Check safety thermostat for proper setting
or beginning of each
season
Operating with safety
thermostat bypass
If thermostat was by
passed for checking
be sure it is back in
the circuit before
starting the unit
Improper circulation of
chilled water
Use ample size clean
able strainer in the
chilled water circuit.
Make sure strainer is
Clean It may some
times be necessary to
chemically tread the
water to prevent for
motion or deposits
System not for winter
shutdown
Be sure and remove
drain plus at end of
cooling season slow
out any residual water
Instead of a suitable
may be added to the
water damage to the
chiller due to freezing
is considered abuse
and is not covered by
the warranty.
Repair
leak
and
recharge
Adjust expansion valve
Open valve or remove
restriction
Remove restriction or
replace filter drier
Replace coil
Clean or replace
Clean
Wire correctly
Clean
Replace
Replace
Clean
Wire correctly
Clean
Examine check valve
Components, clean or
Replace as necessary
11
REMEDY
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